Turn the application of modular powder technique in enclothing a mould to make subtly

The high speed of Chinese automobile industry develops, the character that enclothes a mould to the car raised taller requirement with production cycle, traditional pattern makes means cannot have satisfied market demand. The development direction of current pattern production technology is: Application of technology of computer early days replaces field work stage by stage, with high accuracy treatment replaces later period handiwork to debug stage by stage, mould design, production height is standardized, odd a producer type to automation line producer type develops. Traditional punch technology design adopts DL plan, attention dot depends on shaping quality, to modular face processing compares extensive, numerical control process designing, CNC Machining uses digital-to-analogue face to undertake numerical control process designing directly commonly, on, the treatment means that waits for clearance is used between lower mould face, did not produce the advantage of technology of CNC Machining of three-dimensional model technology and high accuracy, high speed adequately, the modular face design of this kind of production means is to rely on later period to grind actually deserve to debug those who will come true, cause later period to grind deserve to measure repair of do poorly done work over again of big, CNC Machining treatment of repeatability of much, invalid sex is much. And how to alleviate CNC Machining, grind the pressure that deserves to debug working procedure of bottleneck of these two moulds, shorten thereby the problem that whole pattern creates cycle to had become domestic mould industry to be badly in need of solving. The essence that foreign mould precedes the industry had had maturity refines modular face to design a technology, refine digital-to-analogue technology through early days essence, improve primary quality of spare parts T001, shorten the mould grinds match time, shorten finally debug cycle, reduce tone to try cost, promote a spare parts percent of pass quickly. Its model face is designed and debug a process, had formed closed circuit to make a system truly. Change modular powder technique to develop subtly, formulate essence refines modular face to design circuit, blend in a mould to make circuit, specific and main finished technical target is as follows: ① is aimed at large enclothe a mould to be in what heavy load falls to bend be out of shape, use digital-to-analogue whole is out of shape modelling technology will have complement, replace compensation of traditional the treatment that pay part, raise compensation precision, improve efficiency. Round horn of the protruding that because machine remain to bring,② solves, sunken model interferes technical difficult problem. ③ rises to try a model to be led successfully first, improve T001 primary quality, managing compressor the 15% ～ when the stage 20% , shorten the mould debugs cycle 30% . ④ adopts the design of clearance face, improve efficiency of machine tool CNC Machining, when dropping CNC Milling station 10% . 1.

Change 　 of point of flow of work of modular powder technique subtly (1) the job of design phase. Grind in the light of the mould match, debug the circumstance with general and longer cycle, design phase is aimed at the face of model of makings deep space such as the tradition to machine modular face to undertake flow is transformed, through changing the integral appearance of modular face, local form, on the change, the clearance between lower mould will achieve shorten grind match, the purpose that debugs cycle. Make full use of CAE analysis result and mould grind match, the experience that in debugging a process, accumulates, to the problem that exists generally, specific aim ground undertakes relevant modular aspect compensates the development of module beforehand. (2) the job of phase of treatment of numerical control process designing. 2 the clear root in will making a process, empty knives, grind long, press sky of area of work of blade, blame face to leave wait for workload reach to arrive numerical control process designing / phase of modular scale model, ease the pressure of the bottleneck working procedure such as shift of CNC Machining, grip, make can throw greater ability stamping workpiece character to elevate level, shorten then production cycle, improve mould quality. (3) mould production flow optimizes: → of CNC Machining of → of process designing of numerical control of → of model of scale of model of → of directive of TB of → of punch technology design grinds match, debug, form benign closed circuit (see a picture 1) . Build analytic station, indicator card of the clearance that make, indicate modular face design: Include a pattern the modular face that the clearance value of area of actual accord with area, each accord with area, craft asks changes directive of directive of compensation of the hollow of all sorts of the circumstance, change that plays the role that delay a circle, model faces, deflection and obligate compensation. Build station of modular scale model, earlier technology personnel finishs essence of life to refine modular face to design completely according to clearance directive; After waiting for each standard, standard to perfect, build typical part current gap standard, analytic personnel needs to make individual clearance instruction in the light of spare parts characteristic only, the priority that technical personnel indicates by individual clearance directive, current gap completes modular face design. Grind the mould actually at the same time match, the problem that in debugging a process, accumulates undertakes arranging, analytic and file, the working procedure digitlization that uses three-dimensional Photogrammetry detects the modular face after the technology measures burnish, undertake comparative with design model face, build or amend modular face to revise data, the modular surface that forms typical part stage by stage compensates a knowledge base, will coach change modular face to design subtly the next time. 2.

The panel outside the development of obligate modelling technology and application is local model the general character problem that the face caves is all shell plating: Whole is out of shape consist in is like the spare parts with the poorer intensity such as shell plating of coping, boot; Large area is out of shape the place with a consist in local and choppy appearance, the place such as periphery of license plate lamp of fluctuation of column of B of periphery of the handle that be like the door, side wall, boot (see a picture 2) . The hollow of these area is inevitable, also be shell plating the mould grinds match, character promotion gives time the longest, expend the position with the largest energy. Traditional method is to pass sunken model to coerce reduce cave degree, through relapsing spot exercise observes and analyse, undertake adjustment ceaselessly. But sunken model coerces existence effect poor, grind match workload big and adjust round much question. Use model the modelling technology of face obligate will undertake sunken compensating, can solve the problem of the traditional existence that make effectively. The difficulty of this technology is as follows. (1) the correction of class A curved surface. Because cave,produce area to involve class A curved surface commonly, accordingly, in make sure modular face compensates precision while, maintain the pattern of class A curved surface even. For this we established the correction of class A curved surface and evaluation standard, will be out of shape the curved surface of around undertakes the shadow detects, Gao Guang detects and the comparative analysis that sectional line curvature detects, the section that changes to configuration happening needs to undertake correction handling (see a picture 3) . Besides outside the cave in problem of panel, the existence of trend of spring back of partial part general character also is the traditional difficulty issue that affects mould character promotion, like the door in board of hinge place turn round, of place of side wall coping sink and the flange of the spare parts such as coping bonnet is compressed change etc, average size error is bigger a few millimeter differ to ten millimeter, and pure amend again through actual measurement of later period spot need a few sometimes annulus second ability is finished, cave because of what this sums up every spare parts, spring back rule builds obligate of typical spare parts to amend a standard, through early days active obligate reduces later period mould effectively to rectify and reform workload. (2) the application of clearance modelling technology. Differentiate modular face to open area and fundamental area to coerce area, sky, light maintains to arrange between each areas transfer, come true through CNC Machining of high accuracy, high speed microcosmic differ the treatment of clearance model face, reasonable control pattern is different precision of place face CNC Machining, reduced a mould effectively to grind to match and adjust man-hour already so, improved spare parts quality, the treatment efficiency that promoted numerical control equipment again at the same time and effect, shortened effectively the mould designs cycle. Coerce the design of the area: Coerce an area to go up namely, the clearance between lower mould face is less than board makings ply, take a cost commonly - 0.

15 ～ - 0.

05mm, provide stereo to coerce the position and decide. The flow that through reducing clearance to come control plate expects, assure to coerce the dimension precision of area, eliminate corrugate wait for exterior blemish. Open the design of the area for nothing: Increase location go up inside limits, the clearance between lower mould face, basically be to reduce benchwork to grind match an amount, remove the effect that machines remain, machine the control of precision through different area at the same time, improve CNC Machining efficiency, shorten CNC Machining man-hour, its open numerical value to inspect specific place to decide for nothing. The modelling of clearance area: Through CAD software (UG/ThinkDesign) will coerce area, empty curved surface opening an area to cut out break up, have corresponding size, way slant buy or translation, special section should be adopted slant buy + the method of translation. Smooth join comes true through the bridge is received or matching between each area. To outside face, intermediate zone region should enough big, in order to avoid the exterior flaw that sharp change brings. The modular face after clearance modelling is shown 4 times like the graph. ① coerces area position, color patch to indicate red. ② intermediate zone: Clearance face and the tangent curved surface that are not clearance face bridge to receive, it is 5 ～ 20mm commonly, the position is insufficient need not do, two faces intermediate zone makes photograph neighbour the area in clearance. Value of clearance of group of ③ pressing feed is 0.

1mm, sunken model enlarge does not have clearance to be worth; Control feed group other area presses digital-to-analogue. ④ did not note color boundary to press actual label, if local sky opens area too small, bad treatment, can not do. Sky of place of ⑤ sunken R leaves to be worth than digital-to-analogue standard R small 30% . (3) the development of deflection modelling technology and application. As the ceaseless development of processing technique, the pattern uses equipment of numerical control of high accuracy of high rotate speed already generally to undertake model face treatment, its machine precision to already amounted to less than of 5 μ M. However, after be being machined through equipment of rigid numerical control large when enclothing a mould to combine a model, still put in the interference of large area, its grind long quantity is achieved 0.

3 ～ 0.

5mm. Mechanical compressor suffers force to be out of shape sketch map is shown 5 times like the graph. According to deflection distributinging graph decides the mould is out of shape central line (0 lines) , center of computational sunken model is out of shape value, computational deflection is out of shape contour line; According to deflection distributinging graph computation presses feed group center to be out of shape value, computational deflection is out of shape contour line (see a picture 6) . 3.

CNC Machining round horn avoids the development that allows a technology to adopt technique of clearance modelling, deflection modelling reachs application, rose to pull those who extend a pattern to grind considerably close rate, be in however large enclothe pull delay a model to grind in matching a course, still discovered many interference place, main place is in centrally on, between the protruding of lower mould, sunken round horn, via detecting main reason is small diameter the treatment that sunken round horn produces in clear part treatment remains, bring about clearance to reduce the interference that cause. Reduce radius of curvature of modular face reentrant, to it convex horn preserves corresponding modular area changeless, increase thereby on, between lower mould the clearance of round horn place, will compensate small diameter cutting tool to machine rudimental problem. According to the size of curvature radius, its curvature radius narrows accordingly 0.

5 ～ 2mm, assure at the same time with photograph adjacent curved surface between successional. Round horn avoids let technical software if the graph is shown 7 times,apply. 4.

Epilogue passes application of a few years, change modular face to designed a technology to obtain enormous result subtly, rose to try a model to be led successfully first considerably, rose first the character of casting die, shortened the mould grinds match, debug cycle, when the station that dropped machine tool of the press with scarce natural resources, numerical control at the same time, alleviated greatly mould industry exists generally " bottleneck " the pressure of working procedure, brought remarkable economic benefits for the company, basically reflect in: Improved CNC Machining efficiency considerably, shorten CNC Machining time, reduce frequency of repair of CNC Machining do poorly done work over again second, reduce treatment of repeatability, invalid sex; Reduced cutting tool cost; Shortened considerably grind long, debug cycle, reduced sheet to cover mould press to take up when the stage, improved spare parts quality, reduced later period to debug annulus second. With international posture of company of most advanced pattern is compared, home changes modular face design to had approached level of foreign advanced technique subtly at present, but because start later, professional poorer, the difference with arrange and blend in a design to apply link to still have again the feedback of data, collect, certain afresh is debugged in the spot. Believe as experience accumulate, will narrow stage by stage the difference of as banner as abroad technology, form benign loop truly. CNC Milling